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A D V A N C E D
M A T E R I A L S
&
P R O C E S S E S | J U L Y / A U G U S T
2 0 1 5
2 3
Unlike a surface flow medium
where the laminate is flooded with resin,
microweb (at approximately 3 g/m² per
100 g/m² of carbon) allows for an even
flow rate of resin through the thickness
and across the laminate surface. The
web also boosts impact resistance, and
improves shear, compression, and flex-
ural strength. Further, the weight gain is
minimal. While the B53’s strength, stiff-
ness, and weight specifications could
have been met with prepreg construc-
tion, the cost would have been much
higher. GCY co-founder, Roger Hatfield,
believes that while a boat like this might
normally cost $4 million in prepreg, the
B53 came in around $2.5 million.
“It was the new fabric that allowed
us to get air out ahead of the resin front,
instead of entrapping it within the lam-
inate, as is done with wet bagging, and
evenwith prepreg. That’s howwe hit the
weight target as well as the strength re-
quirement for this boat,” says Hatfield.
BOAT-BUILDING PROCESS
Steggall also assisted in the next
production stage—defining the manu-
facturing process for the boat building.
He helped the Gold Coast staff identify
risks that could cause a failure in every
step of the process, from monitoring
and verifying equipment to controlling
the temperature of parts and resin to
optimize viscosity and flow rate.
The improved build process start-
ed out with the validation of smaller,
less highly structurally-loaded panels
before moving on to larger compo-
nents. Some parts were male-molded,
with others using female molds. Some
parts were produced in a one shot pro-
cess with skin-core-skin all infused
together. To save weight, parts with
a complicated geometry were built in
a three-stage process: The outer skin
was resin infused first, then the core
was installed, and finally the inner skin
was infused. ~AM&P
For more information: Philip Steggall
is director of business development,
North America, at Formax, Cutters
Close, Narborough, Leicester, LE19 2FZ,
UK, +1.401.965.5387,
Gold Coast Yachts’ B53 carbon structure. B53 under construction.
B53 during resin infusion.
Launch day, June 5.